OPERATION & MAINTENANCE MANUAL

EFFLUENT TREATMENT PLANT

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 INDEX

1. PREAMBLE

2. DESIGN BASIS

3. PROCESS DESCRIPTION

4. TECHNICAL SPECIFICATIONS

5. PROCESS START- UP & CONTROL

6. PREVENTIVE MAINTENANCE

7. EQUIPMENT MANUALS

8. DRAWINGS

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PREAMBLE

3
 PREAMBLE

The Effluent Treatment Plant has been designed to treat 240 KLD Effluent.

Salient features of treatment plant:

1. The treatment plant consists of Physical and biological processes. The biological process
consists of double stage anaerobic & aerobic systems.

2. For aeration, Diffused Aeration System with imported Diffusers and Air Purging Grids are
provided. Air is supplied through a twin lobe Air Blower of required capacity. This system
ensures fine bubble dispersion and better Oxygen transfer efficiency.

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DESIGN BASIS

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DESIGN BASIS:

I) FLOW : 800-1000/DAY

II) RAW EFFLUENT CHARACTERISTICS :

Parameter Unit Effluent Inlet

Flow ( KLD) m3/hr 800 - 1000

Ph - 5.0 to 9.0
TSS mg / lt. 200- 300
COD mg /lt. 350 - 400
BOD @ 27 ˚ C mg /lt. 150 – 250
Oil & Grease mg /lt. 10 - 20

III) TREATED EFFLUENT CHARACTERISTICS:

Parameter UNIT Sewage

Outlet
Suspended Solids mg /lt. < 5
Bio-Chemical Oxygen Demand (3 days at 27deg C ) mg /lt. < 20

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 PROCESS DESCRIPTION

ETP PROCESS DESCRIPTION

PHYSICAL TREATMENT
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Effluent Treatment plant is constructed to treat 10, 00,000 liter per day waste water generated from
sugar factory by primary physico-chemical treatment and two stage biological treatments.

Raw waste water streams by gravity passes through bar screen chamber. Here large floatable
particles shall be separated manually .After screening, the effluent collected by gravity to the Oil
removal Tank where Oil and Grease shall be removed from the effluent by the mechanism
provided. The effluent is then passed to the Equalization tank .To keep the contents of the
equalization tank effluents in suspended from one number floating type aerator is provided in each
tank.

Effluent from equalization tank shall be fed to flash mixer unit where Lime solution is added to
raise the pH of the effluent. Over flow from flash mixer shall be collected in tube settlers to settle
the suspended solids. Settled sludge sent to sludge drying beds for dewatering. Overflow from
settling tank shall be collected in feed tank. Effluent from the feed tank shall be further treated
biologically to reduce COD and BOD.

BIOLOGICAL TREATMENT

Effluent shall be pumped to anaerobic fixed film digester from feed tank. Major part of organic
load shall be removed here. The anaerobic organisms will degrade the high concentrated organic
matter present in the effluent. In this digester plastic media is used as a medium for attachment of
microorganisms, which will in turn convert the complex organic matter into simple compounds like
CH4, CO2 & H2O. Outlet from anaerobic digester shall be further treated aerobically. Over Flow
from the anaerobic digester is passed to the biological system i.e. Bio-tower (BT). Bio-tower is
designed as a roughening tower for COD/BOD reduction from the influent. Bio-tower is
constructed with civil columns and beam supports .Bio-tower is filled with PVC structured fill
media .Effluent by gravity collected in the BT sump and effluent recycled to the top with the help
of Bio-tower recycling pump. While sprinkling from the top media attached microorganisms will
degrade the organic matter as BOD. Part of effluent sent to next stage treatment by recycling
pipeline, Second stage biological system i.e. ASP System.

Activated sludge process system comprises of aeration tank followed by secondary clarifier. In
aeration tank organic load as BOD shall be degraded by the help of cultivated microbial culture.

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Constant mixed liquor suspended solids (MLSS) will be maintained in aeration tank in definite
proportions by recycling the bio sludge trapped by the secondary clarifier. At aeration tank air shall
be supplied from air blower to the diffused aeration system. Floating type aerators are also provided
at lagoons for the supply oxygen to microorganisms. From dosing tank, nutrients like nitrogen &
phosphorous shall be added to the effluent at aeration tank in the ratio of BOD: N: P as 100: 5: 1

Recycling of bio-sludge from secondary Clarifier will be done by non clog, centrifugal, semi open
type continuous duty suitable capacity sludge recirculation pumps. The overflow from secondary
clarifier meets the norms prescribed by the Concerned Pollution Control Board for safe disposal.
The excess sludge from the primary settling tank& secondary clarifier shall be withdrawn to
proposed sludge drying beds where sludge get dewatered and dried sludge cakes can be used as a
good manure for gardening.

Outlet from secondary clarifier is collected in Chlorine Contact tank where chlorine Solution is
added to kill pathogen bacteria.

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 TECHNICAL
SPECIFICATIONS

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1.0. UNITS & EQUIPMENTS OF E.T.P.
1.1. CIVIL UNITS

SR.NO PARTICULARS QUANTITY

1. Bar Screen Chamber One No.

2. Oil Removal Tank One No.
3. Oil Collection Pit One No.
4. Equalization Tank One No.
5. Lime Dosing Tank One No.
6. Flash Mixer Tank One No.
7. Tube Settler Tank One No.
8. Feed Tank One No.
9. Anaerobic Reactor One No.
10. Bio-Tower One No.
11. Settling Tank One No.
12. Aeration tank One No.
13. Secondary Clarifier One No.
14. Chlorine Contact Tank One No.
15. Sludge Drying Beds Six Nos.
16. Filtrate Chamber Two Nos.
17. Control Panel Room and Lab Two Nos.(1+1)

1.2. MECHANICAL UNITS / EQUIPMENTS

SR.NO. PARTICULARS QUANTITY

1. Bar Screens Two Nos.

2. Oil & Grease Mechanism One No.
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 3. Flash Mixers Two Nos.
4. Lime Dosing Pump One No.
5. Tube Deck Media 12 M3.
6. Sludge Removal Pump Two Nos.
7. Floating Aerator Two Nos.
8. Raw Effluent Feed Pumps Two Nos.
9. AR Feed Pumps Two Nos.
10. Bio-Fills 300 M3/ 166 M3.
11. Bio-Tower Recycling pump Two Nos.
12. Settling Tank feed well One No.
13. Air Blowers Two Nos.
14. Diffusers Fifteen nos.
15. Nutrient Dosing System Two Nos.
16. Secondary Clarifier Mechanism One No.
17. Bio-Sludge Recycling Pump Two Nos.

2.0. TECHNICAL SPECIFICATIONS FOR UNITS & EQUIPMENTS

A. CIVIL UNITS

1. BAR SCREEN CHAMBER

Type : Rectangular
Volume : 5.07 M3.
Size : 1400 x 3000 x 1000mm + 300mmFree Board
Construction : RCC
Description : An open Tank with suitable size. Arrangement for bar screen
fixing MOC of the tank is in complete RCC M20. Internal
water proof plaster and external sponge finish plastering.
External Green colour ISI grade Cement paint two coats.
Internal anti corrosive painting
Quantity : One No.

2. OIL REMOVAL & COLLECTION TANK

Type : Rectangular
Volume : Separation Tank – 27.2 M3
Collection Tank – 1.5 M3
Size : 2000 mm x 8500 mm x 1200 mm SWD + 400 mm FB
1000 mm x 1000 mm x 2000 mm SWD + 500 mm FB
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 Construction : R.C.C. M20 & MS EP
Quantity : One No.

3. LIME DOSING TANK

Type : Square
Volume : 4.05 M3
Size : 1000 mm x 1000mm x 1500mm SWD + 300 mm FB
Construction : MS EP
Quantity : One No.

4. EQUALISATION & COLLECTION TANK

Type : Rectangular
Volume : 600 M3
Size : 10000 mm x 20000mm x 2500mm SWD + 500 mm FB
Construction : MS EP
Quantity : One No.

5. FASH MIXER TANK

Type : Square
Volume : 12.167 M3
Size : 2300 mm x 2300mm x 2000mm SWD + 300 mm FB
Construction : MS EP
Quantity : One No.

6. TUBE SETTLER TANK

Type : Rectangular
Volume : 50.4 M3
Size : 4500 mm x 4000 mm x 3000mm SWD + 300 mm FB

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 Construction : MS EP
Quantity : One No.

7. FEED TANK

Type : Square
Volume : 44.8 M3
Size : 4000 mm x 4000mm x 2500mm SWD + 300 mm FB
Construction : RCC M 20
Quantity : One No.

8. ANAEROBIC REACTOR

Type : Circular, Closed

Volume : 841 M3
Size : 10400 mm x 8900 mm SWD + 1000 mm FB.
Construction : R.C.C M 20
Quantity : One No.

9. BIO-TOWER

Type : Rectangular
Volume : 384 M3
Size : 8000 mm x 8000 mm x 5500 mm SWD + 1000 mm FB.
Construction : R.C.C M 20
Quantity : One No.

10. SETTLING TANK

Type : Circular

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 Volume : 100 M3
Size : 4600 mm x 2500 mm SWD + 500 mm FB
Construction : R.C.C M 20
Quantity : One No.

11. AERATION TANK

Type : Rectangular
Volume : 250 M3
Size : 5000 mm x 10000 mm x 4500 mm SWD + 500 mm FB.
Construction : R.C.C M 20
Quantity : One No.

12. SECONDARY CLARIFIER

Type : Circular
Volume : 381 M3
Size : 9000 mm x 2500 mm SWD + 500 mm FB
Construction : R.C.C M 20
Quantity : One No.

13. CHLORINE CONTACT TANK

Type : Rectangular
Volume : 50.4 M3
Size : 3000 mm x 6000 mm x 2500 mm SWD + 300 mm FB.
Construction : R.C.C M 20
Quantity : One No.

14. SLUDGE DRYING BEDS

Type : Square/Rectangular
Total Area : 210M2

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 Size : 5000 mm x 5000 mm x 1400 mm
Construction : BBM
Quantity : Six Nos.

15. FILTERATE CHAMBER

Type : Rectangular
Volume : 9 M3
Size : 1500 mm x 1500 mm x 2000 mm
Construction : R.C.C M 20
Quantity : Two Nos.

B. MECHANICAL UNITS

I. BAR SCREEN

Application : Screening floatable solids

Location : At Screen Chamber
Type : Manual
Tank Size : 1400 x 3000 x 1000 mm + 500 FB
MOC : MSEP
Quantity : One No.

II. OIL & REMOVAL MECHANISM

Application : To Trap Oil & Fat

Location : Oil & Fat Removal tank
Type : Semi automatic & scraping type
Tank Size : 4.5 x 4.0 x 2.5 mm SWD + 0.3 FB
Rated Power : 0.5 HP
Make : Gaitsu
Quantity : One No.

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III.FLASH MIXER

Tank Size : 1500 x 1500 x 1500 mm SWD + 300 mm FB

Speed : High
Drive : 1.0 HP
Quantity : Two Nos.

IV. LIME DOSING PUMP

Application : Dosing of Lime

Location : Flash Mixer tank
Capacity : 0-500 LPH
Drive : 0.5 HP
Make : Positive Metering
Quantity : One No.

V. TUBE DECK MEDIA

Model : PVC CD TS60

MOC : UV Stabilized virgin PVC Base
Structure : Hexagonal
Colour : Black
Height of media : 750 mm
Working Temp. : 55 0C
Quantity : M3
Make : Cooldek

VI. SLUDGE REMOVAL PUMP

Application : Sludge Removal from TST

Location : At TST
Capacity : 20 M3/Hr
Head : 10 mtrs.
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 MOC of Pump : CI
Drive : 3 HP
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base-plate, coupling guard.
Quantity : Two Nos

VII. FLOATING AERATOR

Application : Mixing & homogenization
Location : At Equalization tank
Type : Slow speed
Shaft : Fully mechanized MS solid shaft with FRP coating or epoxy
Painting
Base : Fabricated & mechanized base frame
Impeller : Inverted cone type world renowned SIMCAR design with non
Clogging blades .The impeller is mechanized at centre.
Impeller MS with FRP coating or epoxy painting.
Floats : FRP coated floats with necessary hooks and nylon ropes.
Wetted Parts : FRP coated /lined of Epoxy painting.
Geared Motors : Bonfligliloli / Elicon & Siemens /Equaliser
Rated Power : 7.5 HP
Quantity : Two Nos

VIII. RAW EFFLUENT FEED PUMP

Application : Raw effluent feed to FMT
Location : At Equalization Tank
Capacity : 42M3 /Hr.
Head : 15 mtrs.
MOC of pump : CI
Pump internals : SS
Drive : 7.5 HP
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base plate. Coupling guard foundation bolts

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 etc.
Quantity : Two Nos.

IX. AR FEED PUMPS

Application : Effluent to the Anaerobic Reactor

Location : At Feed Tank
Capacity : 20M3 /Hr.
Head : 10 mtrs.
MOC of pump : CI
Pump internals : SS
Drive : 3.0 HP
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base plate. Coupling guard foundation bolts
etc.
Quantity : Two Nos.

X. BIO-FILLS

Application : Medium for bacterial attachment and it increases the

Contact Time
Location : Biotower
MOC : PVC
Specific surface area : 93M2/M3
Void Ration (M2/M3) : More than 97%
Thickness : 0.6mm & 0.3mm
Standard Dimensions : 1200 x 600 x 600mm
Max. width of support: 100/150mm
Dry weight : 30kg/m3
Make : Cooldeck / Equivalent
Quantity : 166 M3 & 300 M3Hr.

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XI. BIO-TOWER RECYCLING PUMP

Application : Recycling at Bio-tower

Location : At Bio-tower
Capacity : 60M3/Hr
Head : 10 mtrs.
MOC of Pump : CI
Drive : 7.5 HP
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base plate, coupling, foundation bolts etc.
Quantity : Two Nos.

XII. SETTLING TANK FEED WELL

Application :
Location : At Settling Tank
Tank Size : 4600 Dia x 2500 mm + 500 mm FB
MOC : MS epoxy painted.
Type : Vertical, Cylindrical
Quantity : One No.

XIII. AIR BLOWERS

Location : Near Aeration Tank

Medium Handled : Air
Make : Everest/ Usha/ Equivalent
Air Flow : 300M3/hr
Delivery Pressure : 0.45kg/cm2
Duty : Continuous
Cooling : Air Cooled
Motor HP : 10 HP
Accessories : All accessories as per requirement

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 Quantity : One No.

XIV. DIFFUSERS

Type : Membrane type air diffuser

Construction : The diffuser is a single piece injection
Moulded poly propylene body. A membrane
sleeve surrounds the moulded tube an is kept in
position by two stainless steel clamps. The design of
the membrane sleeve prohibits clogging of the pores which
are self cleaning when air flow/pressure is interrupted .
Make : Rehau, Germany/Equivalent
Distribution : Air distribution channel extending over the
Effective length guarantees an even distribution of air
Quantity : 25 Nos.

XV. NUTRIENT DOSING SYSTEM

Application : Dosing of Lime

Location : Flash Mixer tank
Capacity : 0-100 LPH
Drive : 0.5 HP
Make : Positive Metering
Quantity : Two Nos.

XVI. SECONDARY CLARIFIER MECHANISM

Application : To scrap the settled sludge at the bottom of the

clarifier & to collect the sludge in centre
Location : At secondary clarifier

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 Size : Suitable to10000mm dia tank.
Access Bridge : The full span structural bridge 1000mm support at
centre &5mm thick plate upto railing centre to with
hand railing
Drive : Centre drive
Gearbox/Motor : Elicon/Siemens/Equivalent
Scraping : MS epoxy painted the centre pipe having two
Scraper arms with neoprene rubber squeezes. The floor is
scrapped twice on revolution to collect sludge at the centre.
Feed Well : MS epoxy painted feed well supported from
the bridge with baffle plate
Painting : All wetted parts will be one coat of epoxy Primer & two
coats of epoxy paints & other parts are two coats of enamel
paints. The scraper arms lifting hand operated mechanism is
provided so that in case over loading the complete assembly
can be lifted manually up to 300mm.
Rated power : 1.0 HP & Gear Box
Quantity : One No.

XVII. BIO-SLUDGE RECYCLING PUMP

Application : Recycling sludge at clarifier

Location : At secondary clarifier mechanism
Capacity : 45M3/Hr
Head : 10 mtrs.
MOC of Pump : CI
Drive : 5 HP
Motor Make : Siemens
Pump Make : Johnson
Accessories : Fabricated MS base plate, coupling, foundation bolts etc.
Quantity : Two Nos.

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3.0 ELECTRICAL LOAD LIST

Sl. No. PARTICULARS Quantity Each Total

Load as HP Load as HP
1. Oil & Grease Removal Mechanism 1 0.5 0.5
2. Flash Mixer 1 1.0 1.0
3. Lime Dosing Pump 1 0.5 0.5
4. Sludge removal Pumps (1W+1Sb) 2 3.0 6.0
5. Floating Aerator 2 7.5 15.0
6. Raw Effluent Feed Pump 2 7.5 15.0
7. AR Feed Pump (1W+ 1Sb) 2 3.0 6.0
8. BT Recycling Pump (1 W+1Sb) 2 7.5 15.0
9. Air Blowers (1W+1Sb) 2 10.0 20.0
10. Nutrient Dosing Pumps 2 1.0 1.0
11 Secondary Clarifier mechanism 1 1.0 1.0
12. Bio-Sludge Recycling Pump 2 5.0 10.0
Working Load : 47.5 H.P (62.7 KW)

Total Load : 91.0 H.P (121.3 KW)

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 PROCESS START-UP
&
CONTROL

PROCESS START-UP and CONTROL

As the effluent does not contain organisms to stabilize the Organics present in the effluent it is
necessary to develop sufficient microbial mass or activated sludge in the aeration tank.

PRE-COMMISSIONING TESTS

The process is to be started with properly prepared cow dung solution for the microbial growth.
Addition of sewage directly also help for the growth of bacteria.

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Before a new plant is commissioned it is necessary that all operational and maintenance personnel
should understand the function and location of each process unit, mechanical equipment and
rooting of the pipelines. Following checks should be made before the commissioning of the plant.

• All the mechanical equipments are to be tested for good working condition, properly
lubricated.
• All the tanks and piping are to be clean to ensure from any chocking.
• All the process units and mechanical Equipments should be tested with water for any
leakages and load testing of equipments including motor directions.
• Check all the instruments for normal operation.
• Check all the interlocks if any for proper tripping.

ROUTINE INSPECTION

• Remove accumulation of foreign material from the inlet channel and outlet overflow weirs
regularly.
• All the vertical walls and channels should be cleaned regularly.
• All the mechanical equipment should be inspected regularly for oil levels in the gearboxes
and for any abnormal sound and vibrations. Foundation bolts and coupling bolts are to be
checked.
• Inspect sludge collection and other equipments annually for the induction of corrosion.
• Check the alignment of equipments incase of any noise or foul operation.
• Check oil & grease for equipments

EMERGENCY INSPECTION

In case of serious problem with any unit, feeding should be stopped immediately to that unit.
Remove all the waste water from the unit and inspect carefully the structure, unusual deposition if
any and all moving parts of the equipments. Once the inspection is completed run the equipment in
idle condition and check for any abnormalities. Once it is clear the equipment can be taken back in
to operation.

PLANT START UP

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Before starting the plant, it is essential that performance of the equipments shall be checked for
proper functioning and for any equipment abnormalities.

a. No Load Run of Motors

This is required to be carried out to ensure that the motors are running smoothly without any
problems. To carry out the inspection of motors, disconnect the coupling/belts. Then the motors
shall be kick started and stopped to observe their direction of rotation. If the direction is anti-clock
wise the terminal box shall be opened to change the phase connections. The motors shall run for
about 30 min on no load to check for any abnormality. During this run, one shall observe no load
current of motors, vibrations, noise and bearing temperature for signs of any defects. If no
abnormality is observed, then motors shall be coupled with equipments for testing on onload. If
any defect is observed immediately inform to the supplier/manufacturer for repair/replacement of
the motor.

b. On Load Trail

All the equipments shall be tested onload with normal water before admitting effluent in to the
system. If any abnormality is observed, it shall be taken care before admitting the effluent. During
trial runs with water, motor load and temperature, bearing conditions and vibrations shall be
observed.

c. Plant Shut Down

In case plant needs to be shut down for a considerable period of time, following should be
observed.
Effluent feed shall be stopped to ETP and divert the flow to stand by storage tanks as per
requirement. All the effluent from the system shall be pumped out/drained and all the tanks shall be
cleaned/washed.

PROCESS

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The following procedure shall be followed for starting up the biological system:

Aerobic System

Aerobic reactor shall be filled with reactor. Sufficient culture (Sludge or cow dung solution) shall
be added. Aeration shall be started with blowers to provide oxygen to the attached microorganisms.
Initially feed shall be started with 2% and wait for 3 days. The condition shall be observed for a
positive response then increase the feed to 5%. Then wait for another 3 days and gradually increase
the feed rate@10% for every 3 days. During this process bacterial growth should be checked
regularly and if any abnormalities are observed immediately feed shall be stopped for some time
and observe the conditions if conditions get stabilized admit the effluent. MLSS and SVI shall be
monitored regularly. Air blowers should run continuously. Once the growth is observed feed the
nutrient as per required.

Anaerobic System

Anaerobic reactor shall be filled with reactor. Sufficient culture (Sludge or cow dung solution) shall
be added. Aeration shall be started with blowers to provide oxygen to the attached microorganisms.
Initially feed shall be started with 2% and wait for 3 days. The condition shall be observed for a
positive response then increase the feed to 5%. Then wait for another 3 days and gradually increase
the feed rate@10% for every 3 days. During this process bacterial growth should be checked
regularly and if any abnormalities are observed immediately feed shall be stopped for some time
and observe the conditions if conditions get stabilized admit the effluent. MLSS and SVI shall be
monitored regularly. Air blowers should run continuously. Once the growth is observed feed the
nutrient as per required.

Asp Process Control

Activated Sludge Process comprises of Aeration tank followed by Secondary Clarifier, which shall
be proposed to meet the requirements. In aeration tank organic load as BOD will be degraded by
the help of cultivated microbial culture. Constant Mixed Liquor Suspended Solids (MLSS) shall be
maintained in aeration tank in definite proportions by recycling the bio sludge trapped by the
secondary clarifier. At aeration tank air supplied from air blower/diffused aeration and also floating
type aerators shall be provided to supply oxygen to microorganisms.

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From dosing tank, nutrients as Nitrogen & Phosphorous shall be added to effluent at Aeration Tank
at the ratio of BOD: N: P as 100: 5: 1

Recycling of bio-sludge from secondary clarifier shall be done by non-clog, centrifugal, semi open
type continuous duty & suitable capacity sludge re circulation pump. The overflow from secondary
clarifier –II shall be collected in supernatant tank where chlorine solution shall be added to kill
pathogenic micro-organisms. From here effluent fed to Duel media pressure filter with the help of
pressure pumps to trap suspended solids and connected to Activated Carbon Filter to remove
odour, residual chlorine etc. Outlet from carbon filter shall be treated water & collected in polishing
pond. Treated water meets the norms prescribed by the pollution control board for safe disposal for
on land irrigation / green development.

The excess sludge from DAF, Primary & Secondary Clarifiers shall be withdrawn by gravity to
sludge drying beds for dewatering. Dewatered and dried sludge cakes shall be used as good
manure.

Constant Solids or MLSS

MLSS should be determined by taking a representative sample at three or more locations in the
aeration tank, so that it represents the mixed liquor in the tank.

F/M ratio
Load is measured by BOD or COD tests. COD test needs shorter time than that of BOD test. Once
in the laboratory COD/BOD ratio is established by a series of daily experiments for a period of one
month or so, BOD can also be calculated by the ratio of COD/BOD.

Micro organisms are measured as MLVSS (Mixed Liquor volatile suspended solids). However
MLSS can also be used.

Measuring MLSS is an even cruder approximation of the living organic matter than measuring
MLVSS
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MLVSS is normally 70-80% of the MLSS. The following data is required to calculate F/M ratio.

BOD concentration, mg/l in waste water flowing to the aeration tank

Q, flow rate, m3 /day
MLVSS in mg/l

The following formula is used to calculate F/M ratio

F/M ratio = (BOD, mg/l) * (Q, m3/day)
(MLVSS, mg/l) * V, m3

Where, V = aeration tank volume, m3

SLUDGE VOLUME INDEX (SVI)

Settled sludge volume reading

SVI = on 1 liter graduated cylinder
After 30 minutes X 1000
MLSS concentration

SVI range usually 100 to 150: although higher values may provide good plant operation

Any changes in SVI reading are more important than the reading itself.

If the SVI increases, this means slower settling and it could indicate
- A decreasing sludge age
- Presence of filamentous organisms
- Or changing whether conditions.
SVI can be decreased by reducing by draining of the sludge.
If the SVI decreased (less than 100), there will be pin point flock in the supernatant. This is small
flow that is left behind the rest of sludge settled too fast. It is called stragger floc.

Settling Tank – Sludge Return

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Settling tank serves a dual purpose in the activated sludge process; viz. it provides a clarified
effluent and it also concentrates the MLSS for its return to aeration tank.
To ensure that settling tank is working effectively.
• Check F/M ratio. BOD and COD test results from samples taken over several days should
be used for calculation.
• Compare the F/M ratio with obtained in the past and watch for changes.
• Check oxygen uptake rate. If it is increasing or decreasing, change RAS (Return Activated
Sludge).
• Changes in RAS must be gradual.

Return of Activated Sludge

RAS is determined using solid balance equation.

RAS = Plant flow X MLVSS

Return solids – MLVSS consent

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PREVENTIVE
MAINTENANCE

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 PREVENTIVE MAINTENANCE

EMERGENCY INSPECTION

In case of serious problem with any unit, feeding should be stopped immediately to that unit. Drain
all the waste water from the unit and inspect carefully the structure, unusual deposition, each and
every part, mechanical equipment attached to that unit, etc. All the mechanical equipment should
be made in good working condition. The unit should be cleaned properly before making the same
operational again.

PREVENTIVE MAINTENANCE

The main purpose of preventive maintenance is to avoid break-downs of equipments so as to

minimize the shut down timings. The preventive maintenance shall help in reducing the cost of
break-downs and operational time.
Preventive maintenance of equipment supplied is to be carried out as per the manufacturer’s
operation manuals for this equipment. Specific guidelines for preventive maintenance for major
equipment are suggested in the table below. These guidelines should be adhered wherever
applicable.

PREVENTIVE MAINTENANCE SCHEDULE

Sr. Equipment Maintenance Frequency

No
01. Centrifugal Alignment Check At Commissioning Stage /
Pumps Oil Check / Refill Quarterly
Gland Tightening/ Replacement Weekly
Chocking Clearance Weekly
Quarterly / Monthly / As
Required
02. Air Blowers Alignment Check At Commissioning Stage /
Oil Check / Refill Monthly
V–Belt Tightening/Replacement Weekly
Suction Filter Cleaning Weekly
Monthly / As Required
03. Dosing Emptying and Cleaning Quarterly
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 Tanks
04. Electrical Routine Check Half Yearly
Connections

• All butterfly valves shall be lubricated and operated regularly for easy operation.
• In case of any abnormal sound, vibrations, temperatures in rotating equipment, the same
shall be stopped immediately and check for gear box oil level, bed and foundation bolts,
coupling bolts and Impeller/rotors conditions.
• Plant operator shall monitor the amperage/low voltage regularly and motors may be stopped
in case voltage falls below 380.
• Spare parts for the equipment that are recommended by the manufacturer shall be kept in
stock for ready use.

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DRAWINGS

34
LIST OF DRAWINGS ENCLOSED

1. ETP Process Flow Diagram

2. ETP Layout Diagram

3. P & I Diagram

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